Vehicle-Side Refueling Coupling Arm for Automatic Coil Alignment
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Solution Overview
Problem
Existing refueling systems for electric drive batteries and fluid tanks in movable vehicles are complex, prone to faults, and require manual settings, leading to inefficiencies and increased costs due to the need for sophisticated electronics and software for optimal positioning of charging coils.
Innovation Solution
A multi-part refueling device with a vehicle-side coupling device and a stationary ground coupling device, featuring a manipulator arm and sensors, allows for fully automatic, maintenance-free refueling by simplifying the positioning process through controlled movement of a contact plate to align with the charging coil or tank neck, eliminating the need for complex electromechanics in the ground coupling device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex electromechanical positioning systems with sensors and actuators are used in the ground coupling device, then optimal alignment between charging coils is achieved, but device complexity and cost increase significantly
Solution Approach 1:
Instead of making the ground coupling device movable with complex positioning systems, the invention inverts the approach by making the vehicle-side coupling device movable. The vehicle coupling device is attached to the vehicle and can be moved into position relative to the stationary ground coupling device, thereby achieving alignment without complex ground-based electromechanics
Solution Approach 2:
The complex positioning system with sensors and actuators is extracted from the ground coupling device and relocated to the vehicle-side coupling device. This extraction eliminates the need for sophisticated electronics and software in the ground infrastructure while maintaining alignment capability
2Ease of manufacture
If manual settings and adjustments are required for refueling, then ease of manufacture is improved, but productivity and user-friendliness deteriorate
Solution Approach 1:
The system enables fully automatic refueling where the vehicle-side coupling device autonomously positions itself relative to the ground coupling device using its own actuators and sensors. The process requires no manual intervention for positioning or settings, achieving both automatic operation and system simplicity
Solution Approach 2:
The vehicle-side coupling device is pre-equipped with actuators and sensors that enable it to autonomously perform positioning and alignment actions before refueling begins, eliminating the need for manual setup during the refueling process
3Loss of energy
If the primary charging coil is moved on the floor to optimize positioning, then electromagnetic coupling efficiency is improved, but the complexity of embedding and moving the coil in the ground increases
Solution Approach 1:
Instead of moving the primary charging coil in the ground, the invention inverts the approach by moving the secondary charging coil on the vehicle side. The vehicle coupling device contains the movable charging coil with actuators, while the ground coupling device remains stationary with a fixed primary charging coil
Solution Approach 2:
The movable charging coil mechanism is extracted from the ground coupling device and relocated to the vehicle-side coupling device. This extraction simplifies the ground infrastructure to a stationary primary coil while concentrating the complexity of movement and positioning in the vehicle-mounted secondary coil
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, safe, and cost-effective fully automatic refueling with reduced energy losses and electromagnetic emissions, improving the reliability and simplicity of the refueling process while maintaining optimal energy transfer.
Implementation Method 1
The primary charging coil is typically mounted on the floor of a garage and connected to charging electronics, enabling the generation of an electromagnetic charging field.
Implementation Method 2
Both coils act as electromagnets, attracting and pushing each other depending on the induced current or magnetic field.
Data Source
Figure 1a~1b
Figure 2~3
AI summary
In a multi-part refueling device (1) for refueling an electric traction battery (A) or a fluid tank (B) of a mobile vehicle, simplified and reproducible refueling is to be achieved. This is achieved by the coupling device (connecting means 230) carried on the vehicle side, which is designed as at least one charging coil, in the form of charging contacts or as a charging nozzle (230), and has a manipulator arm (24) for lowering, moving and lowering the contact plate (23) in a center of the stationary ground coupling device (3), wherein the manipulator arm (24) has an upper arm segment (240) pivotably and rotatably mounted on the vehicle side, a joint (241'), a lower arm segment (242) and another joint (241") for attaching the contact plate (23), and is automatically controlled by the computer and control unit (21).